Modular fence system

ABSTRACT

A modular fence system ( 10 ) is provided. The modular fence system  10  generally includes a plurality of spaced post assemblies ( 100 ) for securement to a support surface, and at least one cross member ( 200 ) coupled to respective support portions of at least a pair of such post assemblies ( 100 ) to extend transversely therebetween. Each post assembly ( 100 ) includes first and second molded post members ( 110, 120 ) joined one to the other in opposed manner to define therebetween at least one transverse eyelet ( 105   a   , 105   b   , 105   c ). Each of the first and second post members ( 110, 120 ) is formed with a base section ( 114, 124 ) and a support section ( 112, 122 ) extending longitudinally therefrom. The support section ( 112 ) of the first post member ( 110 ) includes at least one slotted recess ( 115   a   , 115   b   , 115   c ) for defining against the second post member support section ( 122 ) at least a portion of one transverse eyelet ( 105   a   , 105   b   , 105   c ). At least one of the first and second post members ( 110, 120 ) includes a protuberant portion ( 111   a   , 111   b ) for engaging a cavity ( 121   a   , 121   b ) formed in the other of the first and second post members ( 110, 120 ). The cross member ( 200 ) engages respective ones of the transverse eyelets ( 105   a   , 105   b   , 105   c ) of the pair of post assemblies ( 100 ).

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The subject modular fence system is generally directed to a fencestructure for partitioning or peripherally bounding areas of property.More specifically, the subject modular fence system is one whichincludes cross members supported by a plurality of post assemblies,wherein one or more of at least the post assemblies is formed with amodular, molded construction.

[0003] A type of fence system often used, particularly where it is to beof considerable length, is the board type where a plurality of rail-likeboard members are horizontally passed through transverse eyelet openingsformed in a plurality of spaced vertical support posts. Depending onsuch factors as the peripheral contour of the area being fenced,dimensional constraints on the board members, and the spacingrequirements for neighboring posts, individual board members may besupported by two, three, or even more neighboring support posts. Aplurality of sections having boards thus supported by spaced supportposts are extended in series to collectively define a given fencesystem. Such fence systems in many outdoor applications extend overgreat distances.

[0004] A number of practical considerations typically bear on themanufacture and use of such board type fence systems. First, costsescalate to considerable levels because the fence system is often thefence type of choice where the application calls for great fencelengths. Material and fabrication costs may mount to prohibitivelysignificant levels in those applications. Additionally, mostapplications of such fence systems occur outdoors; hence, the fence'sstructural members are continually exposed to the elements. It isimportant for these reasons to form such fences from materials whichafford not only minimal manufacturing costs but provide greatdurability, so as to withstand the constant environmental exposureencountered in typical applications.

[0005] Other points of considerable practical concern are the cost andconvenience of adequately maintaining the fence system over the manyyears of service normally required of such fence systems. Because theyare typically intended to serve at least in some degree a containmentfunction, these fence systems tend to extend in substantially contiguousmanner about the given area of containment. Even where containment isnot a primary function, a substantially contiguous configuration isdesirable to preserve the visual continuity of the partition structureestablished by the fence system. Most fence systems, therefore, areformed with few if any intermediate breaks in their structure.

[0006] Where a repair is to be made at an intermediate portion of thefence system, then, it may become difficult to remove or replace anindividual board or support post member without removing or otherwisedisturbing the surrounding members. Replacing a damaged support postmember, for instance, would require disassembly of the given fencesection, at least to the extent that the section's board members wouldfirst need to be disengaged not only from the particular support postmember in question, but also from the other neighboring support postmember(s) by which the board members is also supported.

[0007] Consequently, there remains a need for a board type fence systemwhose structural members are inexpensive to manufacture yet durableenough to withstand continual environmental exposure and maintainstructural soundness. There remains a need, moreover, for such a fencesystem whose structural members, even at its intermediate sections, maybe accessed for repair or replacement with simplicity and ease.

[0008] 2. Prior Art

[0009] Fence systems of various type are known in the art. The mostrelevant art known to Applicant includes U.S. Pat. Nos. 6,131,885;4,324,388; 4,702,459; 4,240,615; 5,803,438; 4,858,891; 5,931,450;4,540,160; 3,698,692; 4,735,397; 5,601,278; 4,060,222; 4,357,001;6,299,142; 6,173,944; 5,613,664; 6,311,956; 3,955,801; 4,722,514;6,284,336; 5,599,599; 5,255,897; 4,553,741; and, 5,149,060. While thesereferences disclose fence systems of various structure and materialcomposition, there is no fence system heretofore known which providesthe combination of low cost manufacturability, durability, andsimplicity of maintenance to the degree that the subject modular fencesystem provides.

SUMMARY OF THE INVENTION

[0010] A primary object of the present invention is to provide a modularfence system whose structural members are inexpensive to manufacture.

[0011] It is another object of the present invention to provide amodular fence system that is both durable and structurally sound.

[0012] It is yet another object of the present invention to provide amodular fence system that may be easily and conveniently repaired.

[0013] These and other objects are attained by the subject modular fencesystem comprising, generally, a plurality of spaced post assemblies forsecurement to a support surface, and at least one cross member coupledto support portions of two or more such post assemblies to extendtransversely therebetween. Each post assembly includes first and secondmolded post members joined one to the other in opposed manner to definetherebetween at least one transverse eyelet. Each of the first andsecond post members is formed with a base section and a support sectionextending longitudinally therefrom. The support section of the firstpost member includes at least one slotted recess for defining againstthe second post member support section at least a portion of onetransverse eyelet. At least one of the first and second post membersincludes a protuberant portion for engaging a cavity formed in the otherof the first and second post members. The cross member engagesrespective transverse eyelets of the pair of post assemblies.

[0014] In a preferred embodiment, the first and second post members areintegrally molded from a thermoplastic composition, as are each of thecross members. Preferably, the thermoplastic composition includes arecycled plastic resin material that is impact modified and includes apigmentation component. Each cross member is in that embodimentreinforced by a core having a predetermined sectional contour.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015]FIG. 1 is a perspective view of a portion of one embodiment of thepresent invention;

[0016]FIG. 2 is an exploded perspective view of the portion of theembodiment of the present invention shown in FIG. 1;

[0017]FIG. 3 is an elevational view, partially cut away, of oneembodiment of the present invention as assembled in an exemplaryapplication;

[0018]FIG. 3A is an elevational view, partially cut away, of analternate configuration for a portion of the embodiment shown in FIG. 3;

[0019]FIG. 4A is a sectional view in one embodiment of a first portionof the system shown in FIG. 3;

[0020]FIG. 4B is a sectional view in an alternate embodiment of a firstportion of the system shown in FIG. 3;

[0021]FIG. 5 is a sectional view in one embodiment of another portion ofthe system shown in FIG. 3; and,

[0022]FIG. 6 is an elevational view, partially cut away, of variousportions of the embodiment of the present invention shown in FIG. 3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Referring now to FIGS. 1-3, there is shown one exemplaryembodiment of the subject modular fence system 10. Fence system 10includes in this embodiment a plurality of spaced post assemblies 100secured to a support surface 1. Each post assembly 100 is formed byopposing first and second modular post members 110, 120 that adjoin asshown to define a plurality of transverse eyelet openings 105 a, 105 b,105 c therebetween. Fence system 10 further includes in this embodimenta plurality of cross members 200, each of which transversely extends toengage for support corresponding eyelets 105 a, 105 b, 105 c of aplurality of neighboring post assemblies 100.

[0024] In the embodiment shown, a contiguous series of fence sections10′, 10″ is thus defined (two inner ones of which are illustrated inFIG. 3). Each fence section 10′, 10″ includes multiple transverse rowsof board-like cross members 200 supported by a pair of outer postassemblies 100 a and an intermediate post assembly 100 b. Where thegiven fence section adjoins another fence section as shown, the outerpost assembly 100 a closest to the other adjoining fence section servesconcurrently as an outer post assembly for that adjoining fence sectionas well.

[0025]FIG. 3 illustrates but one exemplary configuration for theembodiment of system 10 shown, and numerous other suitableconfigurations may be employed. For example, each section 10′, 10″ mayinclude different numbers of post assemblies 400 and/or cross members200 arranged with uniform or nonuniform relative spacing. As a furtherexample, neighboring fence sections 10′, 10″ may be arranged with anoverlapping delineation. That is, the rows of cross members 200 may belengthwise staggered in arrangement such that cross members 200 indifferent rows terminate at different post assemblies 100 rather than atthe same post assemblies 100 a as shown. The present invention is notlimited to any particular configuration or arrangement of fencesections, as the requirements of various intended applications mayrender certain configurations/arrangements more suitable than others.

[0026] Preferably, the erected fence structure is reinforced byintermittently connecting terminal ends of adjacent cross members 200disposed in the same row using a plurality of fasteners 210. Suchfasteners 210 may be of any suitable type known in the art capable ofsecurely coupling the two opposing cross member ends. At other pointsalong a given row of cross members 200, transversely opposing terminalends of adjacent cross members 200 are preferably left free anduncoupled to permit their relative displacement for accommodating suchthings as vibration, shock, and thermal expansion/contraction.

[0027] An exemplary embodiment is illustrated for inner fence sections10′ and 10″ in FIG. 3, wherein terminal ends of two cross members 200are disposed within post assembly 100 a opposing one another insubstantially abutting manner. In alternate configurations, such asshown in FIG. 3A, the terminal ends of cross members 200′ may bedisposed within post assembly 100 a′ overlapped at respective regions205′. The transverse eyelet opening and/or the terminal end portions ofthe cross members 200′ may be suitably configured in contour anddimension to enable such overlap in this configuration. The overlappingof terminal ends, of course, permits extended lengths in the crossmembers 200′, affording the fence system greater tolerance tocontraction/expansion and displacement of cross members 200′ than in theconfiguration shown in FIG. 3.

[0028] An exemplary embodiment for fence sections 10 a, 10 b disposed atends or corners of the given fence system is illustrated in FIG. 6. Infence sections 10 a, 10 b, cross members 200 are anchored to postassemblies 100 disposed at or near an end/corner by suitable fasteners220. Fasteners 220 are preferably of the self-tapping type and suitablyconfigured to securely affix and retain cross members 200 relative tothe given post assemblies 100.

[0029] Referring back to FIGS. 1-2, each of the first and second moldedpost members 110, 120 of post assembly 100 is integrally moldedpreferably from a thermoplastic composition. Post members 110, 120 maybe formed with various shapes, dimensional proportions, and such otherconfigurational features than those shown, to the extent permitted bythe requirements of the intended application. In accordance with thepresent invention, however, each of the first and second post members110, 120 is formed with a base section 114, 124 sufficiently adapted forstable securement to the ground or other supporting surface, and asupport section 112, 122 extending longitudinally therefrom. The supportsections 112, 122 are suitably configured such that when post members110, 120 are joined in opposed manner, they cooperatively define thetransverse eyelet(s) 105 a, 105 b, 105 c for supportingly receiving thecross member(s) 200 employed in the given application. Accordingly, atleast the first post member 110 is formed with one or more slottedrecesses, each of which defines all or part of a transverse eyelet 105a, 105 b, 105 c against a corresponding portion of the second postmember 120.

[0030] In the exemplary application shown, a plurality of eyelets 105 a,105 b, 105 c are thus defined by a plurality of slotted recesses 115 a,115 b, 115 c formed in longitudinally spaced manner in the first postmember 110. These slotted recesses 115 a, 115 b, 115 c respectivelyoppose and communicate with corresponding slotted recesses 125 a, 125 b,125 c similarly formed into the second post member 120 when the two postmembers 110, 120 are brought together.

[0031] Note that in certain alternate embodiments, the second postmember 120 may, for instance, define simply a flat, unrecessed planarsurface, with the slotted recesses formed (dimensioned accordingly) onlyinto the first post member 110. In the embodiment shown, the slottedrecesses 115 a, 115 b, 115 c and 125 a, 125 b, 125 c separate aplurality of respective coupling bodies 117, 127 defined on the two postmembers 110, 120. These coupling bodies 117, 127 form opposing faceswhich make substantially flush contact one with the other in theembodiment shown, as do the opposed longitudinal base surfaces 119, 129(defined at the respective base sections 114, 124) when the first andsecond post members 110, 120 are joined for fence assembly.

[0032] At least one of the first and second post members 110, 120includes one or more protuberances 111 a, 111 b preferably protrudingfrom a corresponding coupling body 117, 127. Each protuberance 11 a, 11b engages a cavity 121 a, 121 b preferably formed in an opposingcoupling body 117, 127 on the other of the first and second post members110, 120. The protuberances 111 a, 111 b and their receiving cavities121 a, 121 b may be formed on opposing first and second post members110, 120 in any suitable combination and number necessary to ensurereliably guided alignment of the opposed first and second postassemblies 110, 120 when they are brought together for assembly.

[0033] As mentioned in preceding paragraphs, each of the first andsecond post members 110, 120 is molded to a predetermined form usingpreferably a thermoplastic composition. This thermoplastic compositionincludes in the embodiment shown a recycled plastic resin that ispreferably impact modified and pigmented with one or more pigmentationcomponents. The recycled plastic resin employed is preferably of anolefinic recycled type which typically exhibits a dark, blackish color.By incorporating a series of iron oxides as pigmentation components, arange of naturally occurring earth colors such as varying shades ofbrown, blue, gray, and the like may be derived for the molded postassemblies 110, 120. Any suitable molding technique known in the art maybe employed using these and other such components to yield structuralmembers which in texture and general appearance simulate a particulartype of lumber or other fencing material typically employed in theintended application.

[0034] Tremendous savings in material and recurring labor costs may berealized by forming the structural members in this manner. The plasticresin component may be derived from a multiplicity of scrap or virginsources. If necessary, fillers such as talc, minerals, glass, bamboo,kenaf grasses, and the like may also be incorporated to obtain a desiredcombination of material properties.

[0035] Moreover, each of the first and second post members 110, 120 mayin accordance with the present invention be formed with either a solidor non-solid structure. Where formed with a non-solid structure, eachmember 110, 120 may at its various portions include a hollow, honeycomb,or other internal configuration suitable for the given application. Eachof the coupling bodies 117, 127 as well as the base sections 114, 124 ofthe two post members 110, 120 are hollowed to the extent that theydefine respective cavities 117′, 127′, 119′, 129′, so as to minimize theweight of each post member 110, 120 without significantly compromisingthe strength and structural integrity thereof. The actual choice ofstructural configurations and material properties employed will dependupon such factors as the required service life, the load to be borne,and the environmental extremes to be encountered in the intendedapplication.

[0036] Once they are assembled to form a post assembly 100, the firstand second post members 110, 120 may be fastened together by anysuitable means known in the art. Preferably, though, the post members110, 120 are ultrasonically, heat or friction welded together, so as torealize a firm coupling while minimizing the number of extraneouscomponents required and avoiding conspicuous structural alterations.

[0037] While the coupling bodies 117, 127 and longitudinal base surfaces119, 129 of the two post members 110, 120 are configured in theembodiment shown to define opposing faces for flush abutting engagement,they may be formed with other suitable configurations to effect variousother types of engagement. For instance, the opposed coupling bodies117, 127 and base sections 114, 124 may be suitably configured incontour and dimension such that one telescopically engages the other. Insuch embodiments, the need to separately provide protuberances 111 a, 11b and receiving cavities 121 a, 121 b may be obviated, as the couplingbodies 117, 127 and base sections 114, 124 themselves provide thereinforcing and self-guiding engagement of protuberant and receivingcavity portions.

[0038] The modular structure prevailing for each post assembly 100formed in accordance with the present invention not only facilitatesconvenient initial assembly of fence system 10, it facilitates theconvenient repair of fence sections 10′, 10″, 10 a, 10 b even after thefence system has been fully assembled and erected. Where a particularpost assembly 100 is to be repaired or replaced, that post assembly 100may be conveniently removed—without disturbing the surrounding postassemblies 100 and supported cross members 200— by decoupling the postassembly's post members 110, 120, then drawing apart and away from thecross members 200. The repaired or replaced post members 110, 120 may bere-coupled thereafter, at the appropriate position about the crossmembers 200. Similarly, where a particular cross member 200 is to beremoved for repair or replacement, the post assembly 100 a to which, orwithin which, a terminal end of the cross member 200 is fastened, isdisassembled to expose the cross member's fastened terminal end. Oncethe fastening is released, the cross member 200 may simply be slid outof engagement with the eyelets 105 a, 105 b, or 105 c of the given fencesection's other post assemblies 100. The repaired or replaced crossmember 200 may thereafter be slid back into engagement with the otherpost assemblies 100, then refastened to the adjacent cross member 200,with the post members 110, 120 of the previously-disassembled postassembly 100 a being re-coupled one to the other.

[0039] Preferably, each cross member 200 is molded from a thermoplasticcomposition in much the same manner as described in preceding paragraphsfor post members 110, 120. Like post members 110, 120, each cross member200 may be formed with either a solid or non-solid structure, with anysuitable internal configuration permitted by the requirements of theintended application. Where cross members 200 of sufficiently extendedlength are employed, however, an internal reinforcing core 230, 232 isincorporated into each such cross member 200, as shown in the exemplaryembodiments of FIGS. 4A-4B. This reinforcing core 230, 232 may be formedof ferrous metals, non-ferrous metals, or any other suitable material ofcomparable reinforcing strength and rigidity. Each reinforcing core ispreferably formed with a rigidity-enhancing sectional contour, such asthe I-beam contour shown in FIG. 4A, or the C-channel contour shown inFIG. 4B, such that the cross members 200 will not sag or bow betweensupporting post assemblies 100, even after an extended period of use hasoccurred.

[0040] In other alternate embodiments, more than one reinforcing core230, 232 may be incorporated into a cross member 200 to furtherreinforce its strength and rigidity. Two or more reinforcing cores 230,232 sectionally contoured such as shown in FIGS. 4A, 4B may in thoseembodiments be disposed in nested manner within one cross member 200,for instance, to multiply the reinforcement provided.

[0041] Although this invention has been described in connection withspecific forms and embodiments thereof, it will be appreciated thatvarious modifications other than those discussed above may be resortedto without departing from the spirit or scope of the invention. Forexample, equivalent elements may be substituted for those specificallyshown and described, certain features may be used independently of otherfeatures, and in certain cases, certain arrangements of features may bereversed or interposed, all without departing from the spirit or scopeof the invention as defined in the appended claims.

What is claimed is:
 1. A fence system comprising: (a) a plurality ofspaced post assemblies for securement to a support surface, each saidpost assembly including: first and second molded post members joined oneto the other in opposed manner to define therebetween at least onetransverse eyelet, each of said first and second post members having abase section and a support section extending longitudinally therefrom,said support section of said first post member including at least oneslotted recess for defining against said second post member supportsection at least a portion of one said transverse eyelet; at least oneof said first and second post members including a protuberant portionfor engaging a cavity formed in the other of said first and second postmembers; and, (b) at least one cross member coupled to said supportportions of a pair of said post assemblies to extend transverselytherebetween, said cross member engaging respective ones of saidtransverse eyelets of said pair of post assemblies.
 2. The fence systemas recited in claim 1 wherein each of said first and second post membershas formed therein at least one slotted recess, each said slotted recessof said first post member being in open communication with one saidslotted recess of said second post member to define one said transverseeyelet therewith.
 3. The fence system as recited in claim 2 wherein saidfirst and second post members each include a plurality of said slottedrecesses to define a plurality of said transverse eyelets.
 4. The fencesystem as recited in claim 1 comprising a plurality of said crossmembers extending substantially in parallel one with the other, eachsaid cross member passing substantially through corresponding ones ofsaid transverse eyelets respectively of at least a pair of said postassemblies.
 5. The fence system as recited in claim 1 wherein said crossmember includes a reinforcing core embedded therein.
 6. The fence systemas recited in claim 5 wherein said reinforcing core of said cross memberis formed with a sectional contour selected from the group consistingof: a C-channel, and I-beam.
 7. The fence system as recited in claim 1wherein each of said first and second post members is integrally moldedfrom a thermoplastic composition.
 8. The fence system as recited inclaim 1 wherein said thermoplastic composition includes a recycledplastic resin material, said recycled plastic resin material beingimpact modified and including a pigmentation component.
 9. The fencesystem as recited in claim 1 wherein each said cross member isintegrally molded from a thermoplastic composition.
 10. The fence systemas recited in claim 1 wherein: said base sections of said joined firstand second post members define respective longitudinal base surfacesdisposed in substantially flush contact one with the other; and, saidsupport sections of said first and second post members each include aplurality of coupling bodies separated one from the other by one saidslotted recess, said coupling body of said joined first and second postmembers being disposed in substantially flush contact respectively onewith the other.
 11. The fence system as recited in claim 10 wherein eachsaid coupling body has formed therein a hollowing cavity.
 12. The fencesystem as recited in claim 11 wherein said base section of each saidfirst and second post member has formed therein a hollowing cavity. 13.A fence system comprising: (a) a plurality of spaced post assemblies forsecurement to a support surface, each said post assembly including:first and second molded post members detachably coupled one to the otherin opposed manner to define therebetween at least one transverse eyelet,each of said first and second post members being integrally formed instructure, said first and second post members each having a base sectionand a support section extending longitudinally therefrom, said supportsections of said detachably coupled first and second post membersincluding slotted recesses respectively formed therein for cooperativelydefining said transverse eyelet; at least one of said first and secondpost members including a protuberant portion for engaging a cavityformed in the other of said first and second post members; (b) at leastone cross member coupled to said support portions of a pair of said postassemblies to extend transversely therebetween, said cross memberengaging respective ones of said transverse eyelets of said pair of postassemblies.
 14. The fence system as recited in claim 13 wherein saidfirst and second post members each include a plurality of said slottedrecesses to define a plurality of said transverse eyelets, said firstpost member includes a plurality of said protuberant portions, and saidsecond post member includes a plurality of said cavities.
 15. The fencesystem as recited in claim 13 wherein said base sections of saiddetachably coupled first and second post members define respectivelongitudinal base surfaces disposed in substantially flush contact onewith the other.
 16. The fence system as recited in claim 14 wherein saidsupport sections of said first and second post members each include aplurality of coupling bodies separated one from the other by one saidslotted recess, said coupling bodies of said detachably coupled firstand second post members being disposed in substantially flush contactrespectively one with the other, each said coupling body having formedtherein a hollowing cavity.
 17. The fence system as recited in claim 13wherein each of said first and second post members is integrally moldedfrom a thermoplastic composition including a recycled plastic resinmaterial, said recycled plastic resin material being impact modified andincluding a pigmentation component.
 18. A fence system having aplurality of spaced post assemblies for securement to a support surface,each said post assembly comprising: first and second opposed postmembers detachably coupled one to the other to define therebetween aplurality of transverse eyelets for the insert of a plurality of crossmembers respectively therein; said first and second post members andsaid cross members each being integrally molded from a thermoplasticcomposition, and having a base section and a support section extendinglongitudinally therefrom, said support section of each said first postmember and said second post member including a plurality of slottedrecesses, said slotted recesses of said first post member being alignedin open communication with one of said slotted recess of said secondpost member to define one said transverse eyelet; at least one of saidfirst and second post members including a transversely protuberantportion for engaging a cavity formed in the other of said first andsecond post members, the engagement of said transversely protuberantportions and cavity guiding the detachable coupling of said first andsecond post members in substantially aligned manner.
 19. The fencesystem as recited in claim 18 wherein said thermoplastic compositionincludes a recycled plastic resin material, said recycled plastic resinmaterial being impact modified and including a pigmentation component.20. The fence system as recited in claim 19 wherein said recycledplastic resin material includes an olefinic recycled material, saidpigmentation component including an iron oxide constituent.
 21. Thefence system as recited in claim 18 wherein said support sections ofsaid first and second post members each include a plurality of couplingbodies separated one from the other by one said slotted recess, saidcoupling bodies of said detachably coupled first and second post membersbeing disposed in substantially flush contact respectively one with theother, each said coupling body having formed therein a hollowing cavity.22. The fence system as recited in claim 21 wherein said first postmember includes a plurality of said transversely protuberant portions,and said second post member includes a plurality of said cavities,mutually engaging ones of said transversely protuberant portions andcavities being formed respectively on opposed ones of said couplingbodies.